Cellular cushions and methods of fabricating

ABSTRACT

A cellular cushion includes a base, a plurality of hollow cells, and a sealing layer. The base includes at least a first layer and a second layer. The plurality of hollow cells are coupled to the base and extend outwardly from the base. Moreover, the plurality of cells are coupled together in flow communication. The sealing layer is coupled to at least one of the base first and second layers. At least one of the sealing layer and the base defines a plurality of lock pockets, wherein each of the lock pockets is positioned between adjacent hollow cells for selectively controlling flow communication independently to each of the plurality of hollow cells within the cellular cushion.

BACKGROUND OF THE INVENTION

This invention relates generally to cellular cushions, and moreparticularly, to methods and apparatus for fabricating cellularcushions.

Individuals who are confined to wheelchairs may run the risk of tissuebreakdown and the development of pressure sores, which are extremelydangerous and difficult to cure. More specifically, as such individualsare primarily in a seated position for extended periods of time, theirweight may be concentrated in the bonier portions of the individual'sbuttocks. Over time, blood flow to such areas may decrease, causingtissue to break down in these areas.

To facilitate reducing the weight concentration of such individuals, atleast some users seated in at least some known wheelchairs use cellularcushions facilitate distributing the individual's weight over a largerarea and across the individual's buttocks, and to facilitate decreasingtheir weight concentration in smaller areas. At least some knowncellular cushions include a plurality of hollow fluid-filled cells whichproject upwardly from a common base. More specifically, because theplurality of air-filled cells are coupled in flow communication throughthe base, the air within such cells is at the same pressure throughoutthe plurality of cells, and as such, each cell exerts the same pressureagainst an individual's buttocks.

However, although such cushions do facilitate distributing the weightacross the individuals buttocks, the plurality of cells provide lessstability to the seated individual in comparison to a substantiallyplanar seating surface. To facilitate increasing the stability of theuser, at least some known cellular cushions are divided into isolatedzones of cells, wherein the cells of each zone are only in flowcommunication with the cells within their zone. By varying the pressurebetween the isolated zones, the user may be able to increase theirstability on the cellular cushion depending on the physical condition ofthe user. More specifically, the isolated zones may provide onlyslightly more stability to those users that lack muscular strength intheir pelvis and/or thigh regions. Furthermore, such cellular cushionsmay not provide any additional stability to users that have a skeletaldeformity, such as a pelvic obliquity. More specifically, within atleast some known zoned cushions, such cushions may bottom out to providelittle or no cushioning to a user having a skeletal deformity.

BRIEF SUMMARY OF THE INVENTION

In one aspect, a cellular cushion is provided. The cellular cushionincludes a base, a plurality of hollow cells, and a sealing layer. Thebase includes at least a first layer and a second layer. The pluralityof hollow cells are coupled to the base and extend outwardly from thebase. Moreover, the plurality of cells are coupled together in flowcommunication. The sealing layer is coupled to at least one of the basefirst and second layers. At least one of the sealing layer and the basedefines a plurality of lock pockets, wherein each of the lock pockets ispositioned between adjacent hollow cells for selectively controllingflow communication independently to each of the plurality of hollowcells within the cellular cushion.

In another aspect, a cellular cushion is provided that includes a base,a plurality of hollow fluid-containing cells, and a manifold. The baseincludes at least one layer. The plurality of hollow fluid-containingcells are coupled to the base and extend outwardly from the base. Acavity defined within each cell is coupled in flow communication withevery other cell cavity. The manifold is coupled to the base, and atleast one of the manifold and the base also includes a plurality offluid control devices. Each of the plurality of fluid control devices ispositioned between adjacent hollow fluid-containing cells forselectively controlling flow communication between the plurality ofcells such that a fluid pressure within each of the cell cavities isindependently controlled by the lock pockets.

In another aspect, a method of fabricating a cellular cushion isprovided. The method includes forming a first base layer including aplurality of hollow cells that extend outward from the base and are eachcoupled together in flow communication, and coupling a second layer tothe first layer. The method also includes coupling a third layer to atleast one of the first layer and the second layer wherein at least oneof the second layer and the first layer includes a plurality of fluidcontrol devices that are each positioned between adjacent hollow cellsand are each coupled in flow communication, wherein the fluid controldevices selectively control flow communication independently to each ofthe plurality of hollow cells.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary cellular cushion;

FIG. 2 is a plan cross-sectional view of a portion of the cellularcushion shown in FIG. 1;

FIG. 3 is a cross-sectional view of a portion of the cellular cushionshown in FIG. 2 and taken along line 3-3;

FIG. 4 is an exploded view of the cellular cushion shown in FIG. 1, andviewed from the bottom side of the cellular cushion;

FIG. 5 is a plan view of a portion of an alternative cellular cushion;

FIG. 6 is a cross-sectional view of a portion of the cellular cushionshown in FIG. 5; and

FIG. 7 is a partial plan view of an alternative cellular cushionincluding a lock pocket arrangement that may be used with the cellularcushion shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective view of an exemplary cellular cushion 10. FIG. 2is a plan cross-sectional view of a portion of cellular cushion 10. FIG.3 is a cross-sectional view of a portion of cellular cushion 10. FIG. 4is an exploded view of cellular cushion 10. Cushion 10 is flexible andas described herein, is configured for use on an underlying supportsurface, such as, but not limited to a chair seat, a mattress, or awheelchair. Cushion 10 includes a base 12 and a plurality of hollowcells 14. In the exemplary embodiment, base 12 is substantiallyrectangular and includes a forward side 16 and a rear side 18 connectedtogether by a pair of opposing sides 20 and 22. In an alternativeembodiment, base 12 is non-rectangular. In the exemplary embodiment,cells 14 are arranged in a plurality of rows 24 which extendsubstantially across base 12 between sides 20 and 22, and betweenforward and rear sides 16 and 18, respectively. In an alternativeembodiment, cells 14 are arranged in other geometric configurations andnot arranged in rows 24.

Base 12 is flexible and is formed from a plurality of layers 30 that arecoupled together. In one embodiment, base 12 and cells 14 are formedfrom a flexible neoprene. Alternatively, base 12 and cells 14 are formedfrom a non-neoprene material that enables cellular cushion 10 tofunction as described herein. In the exemplary embodiment, a middlelayer 40 and an outer layer 42 are each coupled to a conformal layer 44to form base 12, as described in more detail below. In one embodiment,at least one layer 40, 42, and/or 44 is fabricated from a material thatprevents that specific layer from bonding against the other layers. Inan alternative embodiment, base 12 includes more than three layers 30.In a further alternative embodiment, base 12 only includes conformallayer 44 and middle layer 40.

Conformal layer 44 is formed unitarily with cells 14 such that cells 14are coupled together in an arrangement 48 of air cells 14 such that allcells 14 are in fluid flow communication with each other, as describedin more detail below. In an alternative embodiment, cells 14 acrosslayer 44 are not all coupled together in fluid flow communication, butrather, layer 44 is defined into regions or quadrants of cells 14 thatare coupled together in fluid flow communication with each other, asdescribed in more detail below. More specifically, in the exemplaryembodiment, cells 14 are positioned substantially symmetrically acrossconformal layer 44 within cell arrangement 48, such that adjacent cells14 are separated by a substantially equal distance D₁. In an alternativeembodiment, cells 14 are separated by variable distances. In analternative embodiment, conformal layer cells 14 are coupled together ina different arrangement and/or orientation with respect to each other.

In the exemplary embodiment, conformal layer 44 is molded with cells 14.In an alternative embodiment, cells 14 are coupled to layer 44. In afurther alternative embodiment, cells 14 are formed integrally withlayer 44 using an injection molding process. In the exemplaryembodiment, cells 14 are all identical and each has an identical heightH and because each is substantially circular, each has an identicaldiameter D₂. Alternatively, a plurality of different-sized cells extendfrom base 12.

A plurality of channels 50, known as release-agent channels, extendbetween adjacent cells 14. More specifically, channels 50 are arrangedin X-shaped patterns that extend between four adjacent cells 14.Channels 50 are coupled in sealing contact with conformal layer 44. Inone embodiment, channels 50 are coupled to layer 44 using a silkscreening process. In another embodiment, channels 50 are formedintegrally with conformal layer 44. In a further embodiment, channels 50are coupled to layer 44 using an X-Y printing machine process. In yetanother embodiment, channels 50 are coupled to layer 44 using anadhesive process. In a further embodiment, channels 50 are formed usinga liquid gasket process. In another embodiment, channels 50 are formedusing a spray process. In a further embodiment, channels 50 are coupledto layer 44 using any process that enables channels 50 to couple tolayer 44 such that adjacent cells 14 are coupled together in flowcommunication.

A release agent is contained within each channel 50. The release agentfacilitates ensuring that channels 50 remain substantially unobstructedduring the assembly of cushion 14, such that adjacent cells 14 remain influid flow communication. More specifically, and as described in moredetail below, during assembly of cushion 14, the release agent ensuresthat adjacent cushion layers 30 remain separated to define channels 50.In the exemplary embodiment, the release agent is formed of a lowviscous solution of talc powder and a carrier, such as, but not limitedto alcohol, that is applied using a high volume low pressure (HVLP)sprayer. In another embodiment, the release agent is any solution thatperforms as described herein, and more specifically, prevents thebonding together of the layers 40, 42, and 44, such as, but not limitedto, petroleum-based mixtures.

Middle layer 40 is sized approximately the same size as conformal layer44 as defined by an outer perimeter of each layer 40 and 44. In theexemplary embodiment, layer 40 defines a plurality of fluid controldevices 70 that are coupled together across cushion 10 in fluid flowcommunication. In the exemplary embodiment, fluid control devices 70 areknown as lock pockets. In an alternative embodiment, lock pockets 70extending across layer 40 are not all coupled together in fluid flowcommunication, but rather, layer 40 is defined into regions or quadrantsof lock pockets 70 that are coupled together in fluid flow communicationwith each other to perform as described herein. More specifically, lockpockets 70 are coupled together by a plurality of lock pocket channels72, such that middle layer 40 functions analogous to a manifold. In theexemplary embodiment, lock pockets 70 are substantially circular andeach has a diameter D₃ that is less than a length L₁ of conformal layerchannel 50. In an alternative embodiment, lock pockets 70 arenon-circular.

In another alternative embodiment, cushion 10 does not include lockpockets 70, but rather includes a plurality of other fluid controldevices which operate to perform the same flow communication function aslock pockets 70 as described herein. For example, such control devicesmay include, but are not limited to including, mechanical devices,electromechanical devices, pneumatic devices, hydraulic devices,electrical devices, or magnetic devices.

Lock pockets 70 are arranged in a pattern that extends across layer 40such that each respective lock pocket 70 is positioned substantiallyconcentrically with respect to the center intersection 74 of X-shapedchannels 50, when layer 40 is coupled to conformal layer 44.Accordingly, in this arrangement, when layers 44 and 40 are coupledtogether, lock pocket channels 72 are substantially centered, andextend, between adjacent cells 14. In an alternative embodiment, lockpockets 70 are not concentrically oriented with respect to channelintersection 74, but rather are still positioned relative to channels 50to enable lock pockets 70 and cushion 10 to perform as described herein.

In the exemplary embodiment, lock pockets 70 and lock pocket channels 72are formed within layer 40 by coupling polymers to layer 40. In oneembodiment, the polymers are coupled via a radio frequency weldingprocess, wherein the polymers are positioned across layer 40 in thepattern described above, such that layer 40 may then be coupled toconformal layer 44. In one embodiment, layer 40 is coupled to layer 44with a lamination process. Specifically, in the exemplary embodiment,prior to layer 40 being coupled to layer 44, an adhesive material isapplied to layer 40 such that the adhesive material extendssubstantially across layer 40 between lock pockets 70 and lock pocketchannels 72.

When layer 40 is coupled to conformal layer 44, layer 40 mates insealing contact with areas of conformal layer 44 that extend betweenadjacent cells 14, and around an outer perimeter of each cell 14. Morespecifically, when layer 40 is coupled to layer 44, lock pockets 70 andlock pocket channels 72 are properly oriented relative to cells 14, andare defined against conformal layer 44. In another embodiment, lockpocket channels 72 are defined between layers 44 and 40. The releaseagent prevents layer 40 from sealing against conformal layer 44 in areasdefined by channels 50, such that, as described in more detail below,fluid flow between layers 40 and 44 is only possible through channels50.

After layers 40 and 44 are coupled together, outer layer 42 is coupledto layer 40 such that layer 40 extends between conformal layer 44 andouter layer 42.

Base 12 also includes a pair of inflation/deflation valves 90 and 92that extend from base 12. Valve 90 is known as a fluid locking pocketvalve and is only coupled in flow communication to locking pockets 70via channels 72. Specifically, valve 90 may be selectively opened andclosed to enable fluid to be injected into, or discharged from, lockpockets 70. In an alternative embodiment, base 12 includes a pluralityof inflation/deflation valves 90 and/or 92. More specifically, becauselayer 40 is coupled to conformal layer 44 except at pockets 70, channels72, and channels 50, this enables air to pass between layers 44 and 40through channels 72 and into lock pockets 70. Accordingly, because lockpockets 70 are coupled together in flow communication, valve 90 enablesthe fluid pressure within pockets 70 to be adjusted substantiallysimultaneously, such that the fluid pressure within all lock pockets 70is approximately equal. In the exemplary embodiment, the working fluidsupplied to lock pockets 70 is air. In an alternative embodiment, theworking fluid is any fluid that enables cushion 10 to function asdescribed herein, including, but not limited to, other gases, fluids, orliquids.

Valve 92 is known as a cushion valve and is only coupled in flowcommunication to cells 14 through channels 50. Specifically, valve 92may be selectively opened and closed to enable fluid to be injectedinto, or discharged from, cells 14. More specifically, because layer 40is coupled to conformal layer 44 except at pockets 70, channels 72, andchannels 50, airflow is possible between layers 44 and 40 throughchannels 50 and into cells 14. Accordingly, in the exemplary embodiment,because cells 14 are coupled together in flow communication, when cells14 are initially inflated, and prior to a user 76 being seated oncushion 10, cells 14 are each pressurized to approximately the samefluid pressure. In the exemplary embodiment, the working fluid suppliedto cells 14 is air. In an alternative embodiment, the working fluid isany fluid that enables cushion 10 to function as described herein,including, but not limited to, other gases, fluids, or liquids.

During use, in the exemplary embodiment, initially cushion 10 isinflated by introducing air through valve 92 into channels 50 and cells14. Moreover, in the exemplary embodiment, cells 14 are pressurizedsubstantially equally across cushion 10 and each cell 14 is inflated tohave a generally circular cross-sectional profile. In an alternativeembodiment, cells 14 have a non-circular cross-sectional profile. In afurther alternative embodiment, layer 44 is defined into regions orquadrants of cells 14 that are coupled together in fluid flowcommunication with each other, and cells 14 within each region orquadrant are inflated to substantially the same fluid pressure.Specifically, the fluid pressure of each cell 14 is variably selectableby the seated user 76 based on comfort and/or seated immersionrequirements, and is adjustable by either adding additional air, oropening valve 92 to decrease the pressure in cells 14. Morespecifically, as cells 14 are inflated, adjacent cells 14 contact eachother, such that cells 14 form a generally continuous, and highlydisplaceable, supporting surface that is highly conformable to theseated user 76.

When all of the cells 14 are inflated together, which is normally thecase, the sides of adjacent cells 14 contact each other and form agenerally continuous, but highly displaceable, supporting surface.Moreover, in the exemplary embodiment, because cushion 10 is cellular,the weight of the seated user 76 is distributed broadly with decreasingpeak pressures across the entire area of the user's buttocks andtherefore, cushion 10 dissipates pressures resulting from the weightsupported at the ishia, or bony prominences of the buttocks.

After the fluid pressure within cells 14 is substantially equalized,such that in the exemplary embodiment, each cell 14 containsapproximately the same fluid pressure, air is introduced into lockpockets 70 through valve 90 and channels 72. More specifically, as airis introduced into lock pockets 70, the fluid pressure within pockets 70is increased. Because each pocket 70 is positioned substantiallyconcentrically with respect to the center intersection 74 of X-shapedchannels 50, increasing the pressure within pockets 70 increases anamount of force induced to each center intersection 74. Morespecifically, as force is applied to channels 50, and specifically tointersection 74, flow communication is stopped between the immediatefour cells 14 coupled together by the respective channels 50. In anotherembodiment, the fluid pressure within lock pockets 70 is not sufficientto stop flow communication between the immediate four cells 14 until auser 76 is seated on cushion 10.

Accordingly, fluid flow between cells 14 across cushion 10 is limited bylock pockets 70. As such, cushion 10 facilitates providing a more stableand more secure sitting surface to users 76 in comparison to thatprovided by other known cellular cushions. In particular, cushion 10provides a stable and secure sitting surface even to a user 76 that doesnot have the energy and/or strength to maintain their pelvis in asymmetrical posture, or to those users 76 that may have a fixeddeformity, such as a pelvic obliquity, that requires the sitting surfaceto conform to the user 76 without bottoming out. In addition, cushion 10facilitates reducing sitting fatigue induced to, and increasing posturalcontrol of, the seated user 76. Furthermore, in the exemplaryembodiment, because cushion 10 is not segmented into zones of cells thatare not in flow communication, but rather because all cells 14 arecoupled in fluid flow communication, if a cell 14 develops a leak, theseated user 76 will not bottom out because lock pockets 70 enable onlyfluid pressure to escape from the particular cell 14 that developed theleak, rather than from all cells 14.

In an alternative embodiment, cushion 10 is supplied to the user 76 as atotally enclosed cushion that is pre-pressurized and does not includevalves 90 and 92. Although cushion 10 provides a sitting surface for aseat, in a further alternative embodiment, cushion 10 is used for othercushioning purposes.

FIG. 5 is a plan view of a portion of an alternative cellular cushion200. FIG. 6 is a cross-sectional view of a portion of cellular cushion200. Cushion 200 is substantially similar to cushion 10 (shown in FIGS.1-4) and components in cushion 200 that are identical to components ofcushion 10 are identified in FIGS. 5 and 6 using the same referencenumerals used in FIGS. 1-4. Accordingly, cushion 200 includes a base 202that is substantially similar to base 12 and cells 14. Base 202 isformed from a plurality of layers 204 that are coupled together. Morespecifically, outer layer 42 and an upper layer 210 are each coupled toconformal layer 44 to form base 202. In an alternative embodiment, base12 includes more than three layers 204.

In the exemplary embodiment, upper layer 210 has a cross-sectional areadefined by an outer perimeter that is smaller than the cross-sectionalarea defined by conformal layer 44. Upper layer 210 defines a pluralityof lock pockets 70 therein that are coupled together in flowcommunication. In another embodiment, upper layer 210 has across-sectional area that is approximately the same size, or largerthan, the cross-sectional area of conformal layer 44. More specifically,the cross-sectional area defined by the outer perimeter of upper layer210 is variably selected based on the number of cells 14 containedextending from conformal layer 44, and the associated number of lockpockets 70 and lock pocket channels 72 to be defined therein.Accordingly, in the exemplary embodiment, upper layer 210 extends aroundsubstantially all of cells 14, with the exception of cells 14 positionedin the corners of cushion 200. Specifically, the size, shape, andorientation of layer 210 is variably selected to ensure that lockpockets 70 perform as described herein. More specifically, in theexemplary embodiment, layer 210 is selected to ensure lock pockets 70are each positioned substantially concentrically with respect to thecenter intersection 74 of X-shaped channels 50, when layer 210 iscoupled to conformal layer 44.

In the exemplary embodiment, lock pockets 70 and lock pocket channels 72are formed within layer 210 by polymers that are coupled to layer 210.In one embodiment, the polymers are coupled via a radio frequencywelding process, wherein the polymers are positioned across layer 210 inthe pattern described above, such that layer 210 may then be laminatedto an upper surface 222 of conformal layer 44. Specifically, prior tolayer 210 being coupled to layer 44, an adhesive material is applied tolayer 210 such that the adhesive material extends substantially acrosslayer 210 between lock pockets 70 and lock pocket channels 72.

Upper layer 210 also includes a plurality of openings 224 extendingtherethrough. Each opening 224 is sized to receive at least a portion ofeach cell 14 therethrough when layer 210 is coupled to conformal layer44. Accordingly, in the exemplary embodiment, because cells 14 aresubstantially identical, each opening 224 is sized identically with adiameter D₄ that is slightly larger than cell diameter D₂. Morespecifically, when layer 210 is coupled to conformal layer 44, layer 210couples in sealing contact with areas of conformal layer 44 extendingbetween adjacent cells 14, and around an outer perimeter of each cell14. Accordingly, when layer 210 is coupled to layer 44, lock pockets 70and lock pocket channels 72 are properly oriented relative to cells 14,and are thus between conformal layer upper surface 222 and a lowersurface 228 of layer 210.

After layers 210 and 44 are coupled together, outer layer 42 is coupledagainst conformal layer lower surface 82. Accordingly, in the exemplaryembodiment, conformal layer channels 50 are defined between conformallayer 44 and outer layer 42. The release agent prevents outer layer 42from sealing against conformal layer 44 in areas defined by channels 50.In another embodiment, cushion 200 includes lock pockets 70 definedabove conformal layer 44 and below conformal layer 44.

Base 202 also includes inflation/deflation valves 90 and 92. In theexemplary embodiment, valve 90 is coupled to a bulb pump 232 thatfacilitates air flow into lock pockets 70. In another exemplaryembodiment, both valves 90 and 92 are coupled in flow communicationwithin base 202 to bulb pump 232 through a third valve that isselectively positionable to enable air flow to enter either valve 90 orvalve 92 when bulb pump 232 is activated. It should be noted that othervalving arrangements are possible.

During use, initially cushion 200 is inflated by introducing air throughvalve 92 into channels 50 and cells 14, and then through valve 90 intolock pockets 70 and channels 72. In the exemplary embodiment, cells 14are pressurized substantially equally across cushion 200 and each cell14 is inflated to have a generally circular cross-sectional profile. Inan alternative embodiment, cells 14 have a non-circular cross-sectionalprofile. Specifically, the fluid pressure of each cell 14 is variablyselectable by the seated user 76 based on comfort requirements, and isadjustable by either adding additional air, or opening valve 92 todecrease the pressure in cells 14. More specifically, as cells 14 areinflated, adjacent cells 14 contact each other, such that cells 14 forma generally continuous, and highly displaceable, supporting surface thatis highly conformable to the seated user 76.

When all of the cells 14 are inflated, the sides of adjacent cells 14contact each other and form a generally continuous, but highlydisplaceable, supporting surface. Moreover, because cushion 200 iscellular, the weight of the seated user 76 is distributed broadly withdecreasing peak pressures across the entire area of the user's buttocksand therefore, cushion 200 dissipates pressures resulting from theweight supported at the ishia, or bony prominences of the buttocks.

Furthermore, after cells 14 are inflated, air is introduced into lockpockets 70 through valve 90 and channels 72 such that the fluid pressurewithin pockets 70 is increased. Because each pocket 70 is positionedsubstantially concentrically with respect to the center intersection 74of X-shaped channels 50, increasing the pressure within pockets 70increases an amount of force induced to each center intersection 74. Inone embodiment, the increased fluid pressure within lock pockets 70stops flow communication between each adjacent cell 14. In anotherembodiment, as user 76 sits on cushion 200, the weight of the userinduced to lock pockets 70 increases fluid pressure acting onintersection 74 and causes flow communication to stop between adjacentcells 14.

Accordingly, fluid flow between cells 14 across cushion 200 is limitedby lock pockets 70. As such, cushion 200 facilitates providing a morestable and more secure sitting surface to all users in comparison tothat provided by other known cellular cushions. In particular, cushion200 provides a stable and secure sitting surface even to a user 76 thatdoes not have the energy and/or strength to maintain their pelvis in asymmetrical posture, or to those users 76 that may have a fixeddeformity, such as a pelvic obliquity, that requires the sitting surfaceto conform to the user 76 without bottoming out. In addition, cushion200 facilitates reducing sitting fatigue induced to the seated user 76while also providing enhanced postural control to the seated user 76.Furthermore, because cushion 200 is not segmented, but rather becauseall cells 14 are coupled in fluid flow communication, if a cell 14develops a leak, the seated user 76 will not bottom out on cushion 200because lock pockets 70 enable only fluid pressure to escape from theparticular cell 14 that developed the leak, rather than from all cells14.

FIG. 7 is a partial plan view of an alternative cellular cushion 300including a lock pocket arrangement 302 that may be used with cellularcushion 10 (shown in FIG. 1). More specifically, cushion 300 issubstantially similar to cushion 10 (shown in FIGS. 1-4) and componentsin cushion 300 that are identical to components of cushion 10 areidentified in FIG. 7 using the same reference numerals used in FIGS.1-4. Accordingly, cushion 300 includes cells 14 and a base 304 that issubstantially similar to base 12. Base 302 is formed from a plurality oflayers 306 that are coupled together. More specifically, base 302 isformed with conformal layer 44, outer layer 42 (shown in FIGS. 1, 3, 4,and 6), and a secondary layer 308 that includes a plurality of lockpockets 70.

Conformal layer 44, secondary layer 308, and outer layer 42 are coupledtogether to form base 12. More specifically, in the exemplaryembodiment, secondary layer 308 is substantially similar to middle layer40 (shown in FIGS. 1-4) and is coupled to conformal layer 44 such thatsecondary layer 308 extends between conformal layer 44 and outer layer42. In another embodiment, secondary layer 308 is substantially similarto upper layer 210 (shown in FIGS. 5 and 6) and is coupled to conformallayer 44 such that conformal layer 44 extends between layer 40 and outerlayer 42.

Lock pockets 70 and lock pocket channels 72 are defined within secondarylayer 308 and are arranged in a pre-determined or programmed pattern 320that is variably selected to meet a user's requirements. Moreover, inthe exemplary embodiment, the pattern 320 of lock pockets 70 definessecondary layer 308 into quadrants 321 of cells 14 that do not includelock pockets 70, and as such, are non-controllable by lock pockets 70.Specifically, in the exemplary embodiment, lock pockets 70 are orientedwithin pattern 320 in a substantially plus-sign (+) shape, and ratherthan extending across substantially all of layer 308, pockets 70 aredefined within a pair of rows 322 and 324 that are orientedsubstantially perpendicular to each other. Alternatively, in otherpatterns 320, lock pockets 70 are arranged in other configurations andorientations with respect to secondary layer 308. More specifically, inthe exemplary embodiment, each row 322 and 324 is substantially centeredwith respect to cushion 300, such that rows 322 and 324 intersect at anapproximate center 326 of cushion 300.

Because lock pockets 70 do not extend substantially across cushion 300,quadrants 321 are defined within layer 308 by lock pocket rows 322 and324. Specifically, although cells 14 are coupled in flow communicationacross conformal layer 44, only those cells 14 immediately adjacent rows322 and 324 are effected by, and selectively controllable by lockpockets 70. In another embodiment, only cells 14 defined within eachquadrant 321 are in flow communication, and as such, each quadrant 321includes an inflation/deflation valve 92, and cushion 300 may include aplurality of inflation/deflation valves 90. More specifically, onlythose cells 14 separated by lock pockets 70 are selectivelycontrollable, as described herein with respect to controlling fluid flowcommunication between the cells 14. Accordingly, patterns 320 arevariably selected, based on a plurality of factors, including, but notlimited to the physical limitations and/or demands of the user 76, suchthat cushion 300 facilitates providing the user 76 with varying degreesof control and comfort, without sacrificing stability to the user 76. Itshould be expressly noted that programmable patterns, such as pattern320, may be employed with any cellular cushion that functions asdescribed herein, and as such, is not limited to being used only withcushion 300.

The above-described cellular cushions provide a user with a sittingsurface that is selectively controllable to facilitate increasingstability and comfort to the user. More specifically, the cellularcushions each include a conformal layer that includes a plurality ofcells extending therefrom, wherein each cell extending from theconformal layer is coupled in flow communication with every other cellextending from the conformal. Furthermore, each cellular cushionincludes a layer that defines a plurality of lock pockets therein thatfacilitate selectively controlling fluid flow communication between atleast some of the cells within the cushion. In addition, the lockpockets facilitate preventing the seated user from bottoming out whileseated on the cushion and/or while the user shifts their weight relativeto the cushion. Furthermore, the lock pockets facilitate preventing aplurality of cells from deflating, in the event that an individual cellis punctured. As a result, a cellular cushion is provided whichfacilitates increasing the sitting support and stability provided to aseated user in a cost-effective and reliable manner.

Exemplary embodiments of cellular cushions are described above indetail. Although the cellular cushions are herein described andillustrated in association with seated users, it should be understoodthat the present invention may be used to provide cushioning in aplurality of other uses. Moreover, it should also be noted that thecomponents of each cellular cushion are not limited to the specificembodiments described herein, but rather, aspects of each cushion andfabrication method may be utilized independently and separately fromother methods described herein. For example, each of the above-describedcellular cushions can employ lock pocket patterns as described in FIG.7.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

1. A cellular cushion comprising: a base comprising at least a firstlayer and a second layer; a plurality of hollow cells coupled to, andextending outward from, only one of said first layer and said secondlayer, each of said plurality of cells extends from a root defined atonly one of said first layer and said second layer outwardly to a tip,said plurality of cells coupled together in flow communication via aplurality of channels extending between adjacent said cells, saidplurality of channels aligned substantially within the same plane; and asealing layer coupled to at least one of said base first and secondlayers, at least one of said sealing layer and said base defining aplurality of cavities therein, each of said plurality of cavities ispositioned between adjacent said hollow cells such that each of saidpluralities of cavities is positioned against at least one of saidplurality of channels extending between adjacent said hollow cells, eachof said plurality of cavities is configured to be pressurized forcontrolling flow communication independently to each of said pluralityof hollow cells extending from the same base layer and coupled togetherby said at least one channel within said cellular cushion.
 2. A cellularcushion in accordance with claim 1 wherein said plurality of hollowcells are oriented in rows, said plurality of channels are arranged inX-shaped patterns that extend between pairs of said hollow cells inadjacent rows, each of said channels within said X-shaped patternsintersects, and is coupled in flow communication with, at least oneother channel in said X-shaped patterns, each of said plurality ofcavities is positioned against an intersection of at least two of saidchannels.
 3. A cellular cushion in accordance with claim 2 wherein eachof said channels within said plurality of X-shaped patterns contains arelease agent therein.
 4. A cellular cushion in accordance with claim 3wherein said plurality of X-shaped patterns are coupled to at least oneof said first layer and said second layer.
 5. A cellular cushion inaccordance with claim 3 wherein said plurality of X-shaped patterns arecoupled to said base by at least one of a lamination process, a silkscreening process, an adhesive process, a liquid gasket process, a sprayprocess, and a printing process.
 6. A cellular cushion in accordancewith claim 1 further comprising a first inflation valve coupled only inflow communication to said plurality of hollow cells for changing anoperating pressure only within said plurality of hollow cells.
 7. Acellular cushion in accordance with claim 6 further comprising a secondinflation valve coupled only in flow communication to said sealing layerfor changing an operating pressure only within said plurality ofcavities.
 8. A cellular cushion in accordance with claim 1 furthercomprising a fluid inflator configured to be coupled in flowcommunication through at least one inflation valve to said plurality ofhollow cells and said sealing layer for changing an operating pressurewithin at least one of said plurality of hollow cells and said pluralityof cavities.
 9. A cellular cushion in accordance with claim 1 whereinsaid plurality of cavities are defined by said base second layer, saidhollow cells extending from said first layer, said second layer betweensaid base first layer and said sealing layer.
 10. A cellular cushion inaccordance with claim 1 wherein said plurality of cavities are formedwith said sealing layer, said hollow cells extending from said firstlayer, said first layer between said base second layer and said sealinglayer.
 11. A cellular cushion in accordance with claim 1 wherein saidplurality of cavities facilitate increasing the stability of saidcellular cushion.
 12. A cellular cushion in accordance with claim 1wherein said plurality of cavities facilitate reducing sitting fatigueof a user.
 13. A cellular cushion comprising: a flexible base comprisinga plurality of layers; a plurality of hollow cells coupled to, andextending outward from, only one of said base plurality of layers, suchthat each of said cells extends from a root defined at said base layerto a tip, said plurality of cells comprising at least a first cell, asecond cell, and a third cell coupled together in flow communicationwith each other via a plurality of hollow channels, such that saidsecond cell is between said first and third cells, said plurality ofhollow channels are aligned substantially in the same plane; and asealing layer coupled to said base such that a plurality of fluidcontrol devices are defined by at least one of said base and saidsealing layer, each of said plurality of fluid control devices ispositioned between said plurality of hollow cells such that each of saidfluid control devices is positioned against at least one of saidplurality of hollow channels, such that actuation of said plurality offluid control devices causes said fluid control devices to inducepressure against at least one of said plurality of hollow channels, suchthat said plurality of fluid control devices selectively control flowcommunication independently to each of said first, second, and thirdhollow cells.
 14. A cellular cushion in accordance with claim 13 whereinsaid plurality of fluid control devices facilitate increasing astability to a user seated on said cellular cushion.
 15. A cellularcushion in accordance with claim 13 wherein said plurality of fluidcontrol devices facilitate reducing sitting fatigue of a user seated onsaid cellular cushion.
 16. A cellular cushion in accordance with claim13 wherein said plurality of fluid control devices are formed withinsaid base such that said plurality of fluid control devices arepositioned between said plurality of hollow cells and said sealinglayer.
 17. A cellular cushion in accordance with claim 13 wherein saidsealing layer comprises an upper surface, a lower surface, and aplurality of openings extending therebetween, said sealing layer lowersurface coupled against said base such that each of said plurality ofhollow cells extends upwardly through a respective sealing layeropening.
 18. A cellular cushion in accordance with claim 17 wherein saidplurality of fluid control devices are formed with said sealing layer,such that said sealing layer lower surface is between said base and saidplurality of fluid control devices.
 19. A cellular cushion in accordancewith claim 13 wherein said plurality of hollow channels comprise aplurality of channels arranged in X-shaped patterns extending betweenadjacent said hollow cells, each of said channels in said X-shapedpatterns intersects, and is coupled in flow communication with, at leastone other channel in said plurality of X-shaped patterns.
 20. A cellularcushion in accordance with claim 13 wherein said plurality of hollowchannels comprise a plurality of channels arranged in X-shaped patternsextending between adjacent said hollow cells, said plurality of X-shapedpatterns are coupled to at least one of said sealing layer and saidbase.
 21. A cellular cushion in accordance with claim 20 wherein saidplurality of X-shaped patterns are coupled to at least one of saidsealing layer and said base by at least one of an RF welding process, alamination process, a silk screening process, an adhesive process, and aprinting process.
 22. A cellular cushion in accordance with claim 13further comprising a first inflation valve coupled only in flowcommunication to said plurality of hollow cells for changing anoperating pressure of fluid only within said plurality of hollow cells.23. A cellular cushion in accordance with claim 22 further comprising asecond inflation valve coupled only in flow communication to saidsealing layer for changing an operating pressure within said pluralityof fluid control devices.
 24. A cellular cushion comprising: a basecomprising at least one layer; a plurality of hollow fluid-containingcells coupled to, and extending outward from, only one of said layers ofsaid base, each of said cells extends outward from a root defined atsaid layer to a tip, a cavity defined within each said cell coupled inflow communication with every other cell cavity through a plurality ofchannels extending between adjacent said cells, said plurality ofchannels are aligned substantially in the same plane; and a manifoldcoupled to said base, at least one of said manifold and said basefurther comprises a plurality of fluid control devices, each of saidplurality of fluid control devices is positioned between adjacent pairsof said plurality of hollow fluid-containing cells such that each ofsaid fluid control devices is against at least one of said plurality ofchannels for selectively controlling flow communication between adjacentcells such that a fluid pressure within each of said cell cavitiesextending from the same layer and coupled together in flow communicationby said plurality of channels is independently controlled by saidplurality of fluid control devices.
 25. A cellular cushion in accordancewith claim 24 wherein said manifold plurality of fluid control devicesfacilitate at least one of increasing a stability to a user seated onsaid cellular cushion, and reducing sitting fatigue of a user seated onsaid cellular cushion.
 26. A cellular cushion in accordance with claim24 wherein said manifold comprises a plurality of openings extendingtherethrough, each of said plurality of hollow fluid-containing cellsextends through a respective one of said plurality of manifold openings.27. A cellular cushion in accordance with claim 26 further comprising asealing layer coupled to said base such that said base is between saidmanifold and said sealing layer.
 28. A cellular cushion in accordancewith claim 24 further comprising a sealing layer coupled to said basesuch that said manifold is between said base and said sealing layer. 29.A cellular cushion in accordance with claim 24 wherein said plurality ofchannels are arranged in a plurality of X-shaped patterns that extendbetween adjacent said cells.
 30. A cellular cushion in accordance withclaim 29 wherein said plurality of X-shaped patterns are coupled to atleast one of a sealing layer and said base using at least one of an RFwelding process, a lamination process, a silk screening process, anadhesive process, and a printing process.
 31. A method of fabricating acellular cushion, said method comprising: forming a first base layerincluding a plurality of hollow cells that extend outward from the samebase layer and are each coupled together in flow communication via aplurality of channels extending between adjacent hollow cells, whereinthe first base layer and the plurality of hollow cells are formedintegrally together, and wherein each of the hollow cells extendsoutward from a root defined adjacent the first base layer to a tip;coupling a second layer to the first layer such that the plurality ofchannels are aligned substantially in the same plane; and coupling athird layer to at least one of the first layer and the second layerwherein at least one of the second layer and the first layer includes aplurality of fluid control devices that are each positioned betweenadjacent hollow cells and against at least one of the plurality ofchannels, and such that each of the plurality of fluid control devicesare coupled together in flow communication, and wherein the plurality offluid control devices induce pressure against at least one of saidplurality of channels to control flow communication independently toeach of the plurality of hollow cells coupled together by the at leastone channel.
 32. A method in accordance with claim 31 wherein forming afirst base layer including a plurality of hollow cells that extendoutward from the same base layer and are each coupled together in flowcommunication further comprises coupling each of the hollow cellstogether using a plurality of channels arranged in X-shaped patternsthat extend between rows of adjacent hollow cells.
 33. A method inaccordance with claim 31 wherein forming a first base layer including aplurality of hollow cells that extend outward from the same base layerand are each coupled together in flow communication further comprisescoupling the plurality of hollow cells together using a plurality ofchannels arranged in a plurality of X-shaped patterns that extend alonga surface of at least one of the first and second layers.
 34. A methodin accordance with claim 31 wherein coupling each of the hollow cellstogether using a plurality of channels arranged in X-shaped patternsfurther comprises injecting a release agent into each channel within theX-shaped patterns.
 35. A method in accordance with claim 31 whereincoupling a second layer to the first layer further comprises couplingthe second layer to the first layer using at least one of an RF weldingprocess, a lamination process, and an adhesive process.
 36. A method inaccordance with claim 32 wherein coupling a third layer to at least oneof the first layer and the second layer further comprises coupling thethird layer to the first layer such that the first layer is between thesecond and third layers.
 37. A method in accordance with claim 31wherein coupling a third layer to at least one of the first layer andthe second layer further comprises coupling the third layer to thesecond layer such that the second layer is between the first and thirdlayers.
 38. A method in accordance with claim 32 wherein coupling athird layer to at least one of the first layer and the second layerfurther comprises: inserting the plurality of hollow cells through aplurality of openings formed within the third layer, such that eachrespective hollow cell extends through a respective third layer opening;and coupling the third layer to the first layer such that the firstlayer is between the second and third layers.